Case study | Energy Saving Doors

A Case Study & Typical Timelines

Evaluating Cost Savings with High‑Speed Doors

The first step for a manufacturing company considering upgrading to high‑speed doors is recognising where the biggest losses and savings lie. In many UK industrial buildings, large doorways—such as loading bays, warehouse entrances and internal segregation points—are major sources of energy waste. Each time a conventional industrial door remains open or moves slowly, conditioned air (heated or cooled) escapes and external air enters, forcing HVAC systems to work harder.

The facility’s energy manager will begin by gathering baseline data: monthly energy bills, heating/cooling usage during peak and off‐peak periods, frequency of door openings, traffic flows in and out of key entrances, indoor vs outdoor temperature differentials, and any complaints about thermal comfort or drafts. Simultaneously, a walk‑through audit of door zones is conducted: how many times the doors open per hour, how long they remain open, how well seals perform, any visible damage or draft paths, and the age/condition of existing doors.

With this data, the company can estimate potential savings from replacing conventional doors with rapid‐action, high‑speed doors. These doors open and close faster, reducing open time, they typically have better sealing and insulation, and they can be automated or sensor‐operated to reduce human error in leaving doors open. The cost savings might be estimated by modelling the reduction in air‑exchange rates, improved thermal control, lower heating/cooling demand, and improved production/throughput from faster door cycles.

For example, if the audit reveals that a loading bay door remains open for an average of 30 seconds per cycle and cycles 200 times per day, switching to a high‑speed door that reduces open time to 10 seconds could cut 20 seconds * 200 = 4,000 seconds (≈ 66 minutes) of open time each day. With known airflow and temperature differential data, that can equate to a significant kWh saving over a year. Combined with better insulation/sealing, the energy cost reduction becomes compelling.

In parallel, non‑energy benefits are quantified: improved throughput (vehicles don’t wait as long), reduced drafts and staff discomfort, fewer cold spots, lower maintenance (less wear/tear on slow doors) and improved safety/compliance. All these help build the business case.

Timeline stage: Weeks 1‑2

Week 1: Kick‑off meeting, baseline data collection (utility bills, door usage logs, condition inspection)
Week 2: Energy audit and door‑zone survey, estimate of potential savings and pay‑back period.

Exploring Grant Funding Options & Preparing Application

Once the business case is drafted, the next phase is exploring funding/grant opportunities to help offset the capital cost of installing high‑speed doors. In the UK, there are schemes aimed at industrial energy efficiency and decarbonisation. For example, the Industrial Energy Transformation Fund (IETF) supports manufacturing businesses investing in energy‑efficient technologies.

Regional or local business growth hubs may also offer grants for energy efficiency (e.g., small‑business efficiency grants).

In this phase, the project team will:

Review eligibility criteria of relevant grant schemes (e.g., minimum energy savings required, project size, business size).
Map the high‑speed door upgrade against those criteria: Does it deliver measurable energy savings? Will documentation be available? Does the business size and sector match?
Initiate pre‑application work: gather required documents (rated energy audit, baseline energy use, project specification for doors, cost estimates from suppliers, anticipated savings and ROI).
Select preferred high‑speed door supplier and get budget quote including installation, commissioning, training, maintenance.
Draft a grant application, which often includes project plan, timeline, cost‑benefit calculation, implementation risk management, and monitoring plan.

Timeline stage: Weeks 3‑6

Week 3: Identify relevant grant schemes and review eligibility.
Week 4: Gather required baseline data and supplier quotes.
Week 5: Draft application documents and internal approvals.
Week 6: Submit grant application.

Grant Evaluation & Approval

After submission, the business awaits grant decision. Most schemes will review applications for completeness, eligibility, value for money, and carbon/energy saving impact. There may be a scoring system, and sometimes a site visit or additional questions from the grant administrator.

During this period, the business should avoid committing to purchase or installation until grant approval is secured (unless funder allows advance procurement). The supplier may hold budget quotes for 30‑60 days; extend if necessary.

If approved, the grant letter will specify funding amount (often a percentage of eligible costs), payment terms (e.g., part up‐front, part on completion), documentation requirements (invoices, installation photographs, energy savings verification) and reporting obligations.

Timeline stage: Weeks 7‑10

Weeks 7‑8: Grant administrator reviews application, may request clarifications.
Weeks 9‑10: Grant approval received (typical 6‑10 weeks), funding agreement signed.

Procurement & Installation of High‑Speed Doors

With grant approval in hand, the project moves into procurement and installation. Activities here include:

Issuing the purchase order to the supplier of the high‑speed doors.
Finalising technical specification: door size, opening speed, insulation, sensors, control systems, safety features, integration with building management or logistics systems.
Scheduling installation to minimise disruption—often during planned plant shutdown or low‑throughput period.
Site preparation: removing old doors, verifying structural supports, ensuring electrical/network connections for sensors and controls, ensuring safety compliance.
Installing the doors: supplier’s engineers fit the new high‑speed doors, test cycle speeds, seals, safety systems, automation and integration.
Commissioning: confirm that doors operate at specified speed, not leaking conditioned air, sensors working, safety interlocks in place.
Staff training: facility operators are briefed on correct door usage, benefits of minimising open time, maintenance routines (seal checks, sensor calibration).
Warranty and maintenance plan: establish schedule for service visits, monitoring of door cycles, record of any overrides or faults

Timeline stage: Weeks 11‑14

Week 11: Order placed, site prep begins.
Week 12: Removal of old doors and site works.
Week 13: Main installation of high‑speed doors.
Week 14: Commissioning, training, hand‑over

Monitoring, Validation & Energy Savings Realisation

After installation, the business begins monitoring actual performance and energy savings. This is vital both for internal benefits and for satisfying grant reporting requirements. Key tasks:

Collect post‑installation energy consumption data (HVAC loads, door‑zone heat loss metrics, cycle counts for doors).
Compare with baseline period to calculate actual savings—e.g., kWh reduction, cost savings, reduced CO₂ emissions.
Monitor door performance: cycle count data from the control system, average open‑time per cycle, number of non‑routine open events, maintenance/fault logs.
Staff feedback: Are drafts reduced? Are throughput times improved? Are HVAC loads more stable?
Report to grant funder: submit invoices, certificates of installation, monitoring results, savings calculations, and any required case‑study summary.

Internally, the business updates its ROI model—if savings exceed predictions, the payback period reduces further.

Timeline stage: Months 1‑12 post‑installation

Month 1: Data gathering begins.
Month 3: Preliminary energy savings reviewed.
Month 6: Interim report produced; adjustments made (e.g., staff behavior around doors).
Month 12: Full year‑on‑year comparison of energy usage, cost savings, door performance, and payback calculation.

Realistic Timeline Summary

Putting it all together, a typical timeline for a high‑speed door upgrade with grant funding might look like this:

Weeks 1‑2: Audit, baseline data collection, savings estimate
Weeks 3‑6: Grant research, supplier quotes gathered, application drafted and submitted
Weeks 7‑10: Grant evaluation and approval
Weeks 11‑14: Procurement, installation and commissioning
Month 1 onwards: Monitoring begins
Month 3: Interim review
Month 6: Adjustments based on usage and performance
Month 12: Full annual review and validation of savings/payback

From start to full annual review of savings, you’re looking at roughly 12–14 months. However, the major installation and savings realisation occur within the first 3–6 months post‑installation.

Best Practices & Tips for Maximising Success

Early engagement with a specialist high‑speed door supplier: To ensure the solution is correctly sized, specified and integrated, and to help build the savings model.
Robust baseline data: The more accurate your baseline (door cycles, open times, HVAC loads), the stronger your business case and grant submission.
Avoid committing prematurely: Until grant approval is secured, avoid large capital commitments.
Change management with staff: The fastest door won’t deliver the savings if staff leave it open or override sensors—training is key.
Monitor door use: Most high‑speed doors come with cycle counters or control system logs—use them to track performance.
Behavioural reinforcement: Encourage employees to minimise open time, report issues promptly, keep seals clean and functioning.
Report early and clearly: Many grant funders require timely reporting—plan for this from the outset.
Plan for maintenance: Scheduled maintenance ensures performance remains high and savings are sustained long‐term

Conclusion

Upgrading to high‑speed doors is a strategic investment for manufacturing facilities seeking to reduce energy consumption, improve operational efficiency and qualify for grant funding. The process—from identifying savings potential through the audit, securing grant support, installing the doors and realising energy and cost reductions—can typically be completed within a 12‑month period from start to full savings validation. With careful planning, strong baseline data, grant readiness and supplier collaboration, businesses can deliver substantial returns, enhanced workflow and improved environmental performance.

For any facility considering such a project, this timeline and process serve as a blueprint: an audit, grant application, installation, monitoring and savings realisation. Taking advantage of UK grant schemes for energy efficiency and combining them with high‑speed door technology offers a clear path to both operational and sustainability gains.